US20110171570A1 - Electrophotographic photoreceptor, method of producing same, process cartridge, and image forming apparatus - Google Patents

Electrophotographic photoreceptor, method of producing same, process cartridge, and image forming apparatus Download PDF

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US20110171570A1
US20110171570A1 US12/860,406 US86040610A US2011171570A1 US 20110171570 A1 US20110171570 A1 US 20110171570A1 US 86040610 A US86040610 A US 86040610A US 2011171570 A1 US2011171570 A1 US 2011171570A1
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content
mass
fluoro
approximately
alkyl group
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Inventor
Hitoshi Takimoto
Masahiro Iwasaki
Daisuke Haruyama
Hidemi Nukada
Mitsuhide Nakamura
Koji Bando
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Fujifilm Business Innovation Corp
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Fuji Xerox Co Ltd
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Assigned to FUJI XEROX CO., LTD. reassignment FUJI XEROX CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BANDO, KOJI, Haruyama, Daisuke, IWASAKI, MASAHIRO, NAKAMURA, MITSUHIDE, NUKADA, HIDEMI, TAKIMOTO, HITOSHI
Publication of US20110171570A1 publication Critical patent/US20110171570A1/en
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    • G03G5/14Inert intermediate or cover layers for charge-receiving layers
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    • G03G5/14713Macromolecular material
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    • G03G5/0763Polymeric photoconductive materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds having a photoconductive moiety in the polymer backbone comprising arylamine moiety
    • G03G5/0766Polymeric photoconductive materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds having a photoconductive moiety in the polymer backbone comprising arylamine moiety benzidine
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    • G03G5/076Polymeric photoconductive materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds having a photoconductive moiety in the polymer backbone
    • G03G5/0767Polymeric photoconductive materials obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds having a photoconductive moiety in the polymer backbone comprising hydrazone moiety
    • GPHYSICS
    • G03PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
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    • G03G5/00Recording-members for original recording by exposure, e.g. to light, to heat or to electrons; Manufacture thereof; Selection of materials therefor
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    • G03G5/00Recording-members for original recording by exposure, e.g. to light, to heat or to electrons; Manufacture thereof; Selection of materials therefor
    • G03G5/14Inert intermediate or cover layers for charge-receiving layers
    • G03G5/147Cover layers
    • G03G5/14708Cover layers comprising organic material
    • G03G5/14713Macromolecular material
    • G03G5/14747Macromolecular material obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • GPHYSICS
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    • G03G5/00Recording-members for original recording by exposure, e.g. to light, to heat or to electrons; Manufacture thereof; Selection of materials therefor
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    • G03G5/14713Macromolecular material
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    • GPHYSICS
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    • G03G5/14708Cover layers comprising organic material
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    • G03G5/14786Macromolecular compounds characterised by specific side-chain substituents or end groups

Definitions

  • the invention relates to an electrophotographic photoreceptor, a method of producing the electrophotographic photoreceptor, a process cartridge, and an image forming apparatus.
  • an electrophotographic image forming apparatus has the following structure and processes. Specifically, the surface of an electrophotographic photoreceptor is uniformly charged by a charging means to desired polarity and potential, and the charged surface of the electrophotographic photoreceptor is selectively removed of charge by subjecting to image-wise exposure to form an electrostatic latent image. The latent image is then developed into a toner image by attaching a toner to the electrostatic latent image by a developing means, and the toner image is transferred to an image-receiving medium by a transfer means, then the image-receiving medium is discharged as an image formed material.
  • FIG. 1 is a schematic partial cross-sectional view showing the electrophotographic photoreceptor according to a first exemplary embodiment of the first aspect of the invention
  • FIG. 3 is a schematic partial cross-sectional view showing the electrophotographic photoreceptor according a third exemplary embodiment of the first aspect of the invention.
  • FIG. 4 is a schematic view showing an image forming apparatus according to an exemplary embodiment of another aspect of the invention.
  • FIG. 5 is a schematic view showing an image forming apparatus according to another exemplary embodiment of another aspect of the invention.
  • An exemplary embodiment of one aspect of the invention is an electrophotographic photoreceptor (hereinafter, simply referred to as “photoreceptor” in some cases) has at least a substrate, a photosensitive layer provided on the substrate, and an overcoat layer provided on the photosensitive layer.
  • the overcoat layer of the photoreceptor contains at least: a cross-linked component that is obtained by cross-linking of at least one selected from a guanamine compound or a melamine compound and a charge-transporting material having at least one substituent group selected from —OH, —OCH 3 , —SH, or —COOH; fluoro-resin particles; and a fluoro-alkyl group-containing copolymer.
  • the ratio of fluorine atom present in the outermost surface of the overcoat layer as measured with energy dispersive X-ray analysis (EDS) is from approximately 1.0% by mass to approximately 20.0% by mass.
  • the photoreceptor according to the exemplary embodiment has the ratio of the fluorine atom present in the outermost surface of the overcoat layer that is within the range of from approximately 1.0% by mass to approximately 20.0% by mass. Namely, the fluoro-resin particles are exposed in the outermost surface of the photoreceptor according to the exemplary embodiment.
  • the fluoro-resin particles may not be sufficiently exposed in the outermost surface.
  • the fluoro-resin particles are exposed in a manner that the ratio of fluorine atom present is in the aforementioned range.
  • the ratio of fluorine atom present in the outermost surface of the overcoat layer may be preferably from approximately 1.5% by mass to approximately 12.0% by mass, and may be more preferably from approximately 1.5% by mass to approximately 8.0% by mass.
  • the measurement of the ratio of fluorine atom present in the outermost surface of the overcoat layer is carried out by using “TED-2300F” (trade name) manufactured by JEOL Ltd. at an acceleration voltage of 10 kV.
  • the overcoat layer may be formed by applying a coating liquid that satisfies the following requirements (1) to (3) on the substrate, and then by performing cross-linking.
  • the ratio of the sum of the content of the guanamine compound and the content of the melamine compound to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles and the content of the fluoro-alkyl group-containing copolymer is from approximately 0.1% by mass to approximately 20% by mass;
  • the coating liquid contains at least a cyclic aliphatic ketone compound.
  • the ratio of the sum of the content of the guanamine compound and the content of the melamine compound to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles and the content of the fluoro-alkyl group-containing copolymer may be more preferably from approximately 0.1% by mass to approximately 10.0% by mass, and further preferably from approximately 0.5% by mass to approximately 5.0% by mass.
  • the ratio of the content of the charge-transporting material to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles and the content of the fluoro-alkyl group-containing copolymer may be more preferably from approximately 90% by mass to approximately 99.9% by mass, and further preferably from approximately 95.0% by mass to approximately 99.5% by mass.
  • the number of carbon atoms that compose the ring of the cyclic aliphatic ketone compound contained as a solvent in the coating liquid for forming the overcoat layer may be preferably from 4 to 7, and more preferably from 5 to 6.
  • the number of carbon atoms is 4 or more, the compound may become stable when it is heated.
  • the number of carbon atoms that compose the ring is 7 or less, the boiling point of the compound may not be too high and the compound may be easily vaporized by heating upon forming the overcoat layer.
  • X represents an alkylene chain, a halogen-substituted alkylene chain, —S—, —O—, —NH— or a single bond;
  • Y represents an alkylene chain, a halogen-substituted alkylene chain, —(C z H 2z-1 (OH))— or a single bond; z represents an integer equal to or larger than 1; and Q represents —O— or —NH—.
  • the use of the copolymer that contains the repeating unit represented by Structural Formula (1) and the repeating unit represented by Structural Formula (2) as the fluoro-alkyl group-containing copolymer may facilitate to improve the dispersability of the fluoro-resin particles in the coating liquid when the overcoat layer is formed and to suppress flocculation of the fluoro-resin particles. Therefore, the fluoro-resin particles may keep a state of small particle size, and the opportunity at which the fluoro-resin particles expose to the outermost surface may be increased. As a result, the ratio of fluorine atom present in the outermost surface of the overcoat layer may be regulated within the range of from approximately 0.1% by mass to approximately 20% by mass.
  • (C) the fluoro-alkyl group-containing copolymer, and the ratio of fluorine atom present in the outermost surface of the overcoat layer as measured with energy dispersive X-ray analysis (EDS) is from approximately 1.0% by mass to approximately 20.0% by mass.
  • the photosensitive layer according to the exemplary embodiment may be a function-hybridized photoreceptor that possesses both charge-transporting function and charge-generating function or in embodiments, it may be a function separated photoreceptor that is composed of a charge-transporting layer and a charge-generating layer. In embodiments, the photoreceptor may further contain other layers such as an undercoat layer.
  • FIG. 1 to FIG. 3 the configuration of a photoreceptor according to an exemplary embodiment will be described in reference to FIG. 1 to FIG. 3 , but it is construed that the exemplary embodiment is not limited by FIG. 1 to FIG. 3 .
  • FIG. 1 is a schematic cross-sectional view showing one exemplary embodiment of layer configuration of the photoreceptor.
  • the photoreceptor shown in FIG. 1 has a layer configuration in which an undercoat layer 4 , a charge-generating layer 2 A, a charge-transporting layer 2 B, and a protective layer 5 are stacked in this order on a substrate 1 .
  • the photosensitive layer 2 has two layers, namely the charge-generating layer 2 A and the charge-transporting layer 2 B (first exemplary embodiment).
  • the protective layer 5 serves as the overcoat layer.
  • the protective layer 5 contains the essential components of (A) and (B) and satisfies the numerical range of the ratio of fluorine atom present in the outermost surface.
  • FIG. 2 is a schematic cross-sectional view showing another exemplary embodiment of layer configuration of the photoreceptor.
  • the reference marks shown in FIG. 2 are the same as those shown in FIG. 1 .
  • the photoreceptor shown in FIG. 2 has a layer configuration in which an undercoat layer 4 , a charge-generating layer 2 A, and a charge-transporting layer 2 B are stacked in this order on a substrate 1 .
  • the photosensitive layer 2 has two layers, namely the charge-generating layer 2 A and the charge-transporting layer 2 B (second exemplary embodiment).
  • the charge-transporting layer 2 B serves as the overcoat layer.
  • the charge-transporting layer 2 B contains the essential components of (A) and (B) and satisfies the numerical range of the ratio of fluorine atom present in the outermost surface.
  • the photoreceptor shown in FIG. 3 has a layer configuration in which an undercoat layer 4 and a photosensitive layer 6 are stacked in this order on a substrate 1 .
  • the photosensitive layer 6 is a layer in which the functions of the charge-generating layer 2 A and the charge-transporting layer 2 B that are shown in FIG. 1 are hybridized (third exemplary embodiment).
  • the function-hybridized photosensitive layer 6 serves as the overcoat layer.
  • the photosensitive layer 6 contains the essential components of (A) and (B) and satisfies the numerical range of the ratio of fluorine atom present in the outermost surface.
  • a photoreceptor according to the first exemplary embodiment of the first aspect has, as shown in FIG. 1 , the undercoat layer 4 , the charge-generating layer 2 A, the charge-transporting layer 2 B, and the protective layer 5 are stacked on the substrate 1 in this order to form a layer configuration, and the protective layer 5 serves as the overcoat layer.
  • a substrate having the conductivity is employed as the substrate 1 .
  • the substrate include metal plates, metal drums, and metal belts using metals such as aluminum, copper, zinc, stainless steel, chromium, nickel, molybdenum, vanadium, indium, gold, platinum or alloys thereof, and papers, plastic films and belts which are coated, deposited, or laminated with a conductive compound such as a conductive polymer and indium oxide, a metal such as aluminum, palladium and gold, or alloys thereof.
  • conductive means that the volume resistivity is less than 10 13 ⁇ cm.
  • the surface of the substrate 1 is preferably roughened so as to have a centerline average roughness (Ra) of 0.04 ⁇ m to 0.5 ⁇ m.
  • Ra centerline average roughness
  • Examples of the method for surface roughening include wet honing in which an abrasive suspended in water is blown onto a support, centerless grinding in which a support is continuously ground by pressing the support onto a rotating grind stone, and anodic oxidation.
  • Examples of the method for surface roughening further include a method of surface roughening by forming on the substrate surface a layer of resin in which conductive or semiconductive particles are dispersed in the resin so that the surface roughening is achieved by the particles dispersed in the layer, without roughing the surface of the substrate 1 .
  • an oxide film is formed on an aluminum surface by anodic oxidation in which the aluminum as anode is anodized in an electrolyte solution.
  • the electrolyte solution include a sulfuric acid solution and an oxalic acid solution.
  • the porous anodic oxide film formed by anodic oxidation without modification is chemically active, easily contaminated and has a large resistance variation depending on the environment.
  • the anodic oxide film is preferable to conduct a sealing treatment in which fine pores of the anodic oxide film are sealed by cubical expansion caused by a hydration in pressurized water vapor or boiled water (to which a metallic salt such as a nickel salt may be added) to transform the anodic oxide into a more stable hydrated oxide.
  • the thickness of the anodic oxide film may be preferably from 0.3 ⁇ m to 15 ⁇ m.
  • the substrate 1 may have been subjected to a treatment with an acidic aqueous solution or a boehmite treatment.
  • the treatment with an acidic treatment solution comprising phosphoric acid, chromic acid and hydrofluoric acid is carried out as follows: phosphoric acid, chromic acid, and hydrofluoric acid are mixed to prepare an acidic treatment solution preferably in a mixing ratio of 10% by mass to 11% by mass of phosphoric acid, 3% by mass to 5% by mass of chromic acid, and 0.5% by mass to 2% by mass of hydrofluoric acid.
  • the concentration of the total acid components may be preferably in the range of 13.5% by mass to 18% by mass.
  • the treatment temperature may be preferably 42° C. to 48° C.
  • the thickness of a coating film formed thereby may be preferably from 0.3 ⁇ m to 15 ⁇ m.
  • the boehmite treatment may be carried out by immersing the substrate in pure water at a temperature of 90 to 100° C. for 5 to 60 minutes, or by bringing it into contact with heated water vapor at a temperature of 90° C. to 120° C. for 5 to 60 minutes.
  • the thickness of a coating film formed thereby may be more preferably 0.1 ⁇ m to 5 ⁇ m.
  • the film may further be subjected to anodic oxidation using an electrolyte solution which sparingly dissolves the film, such as adipic acid, boric acid, borate salt, phosphate, phthalate, maleate, benzoate, tartrate, and citrate solutions.
  • the undercoat layer 4 has a configuration in which, for example, inorganic particles are contained in a binding resin.
  • the inorganic particles preferably have powder resistance (volume resistivity) of about 10 2 ⁇ cm to about 10 11 ⁇ cm.
  • Examples of the inorganic particles having this resistance value include inorganic particles of tin oxide, titanium oxide, zinc oxide, and zirconium oxide, and in embodiments, zinc oxide may be preferably used.
  • the inorganic particles may be the ones which have been subjected to a surface treatment. Particles which are subjected to different surface treatments, or those having different particle diameters, may be used in combination of two or more kinds.
  • the volume-average diameter of the inorganic particles may be from 50 nm to 2,000 nm, and may be preferably from 60 nm to 1,000 nm.
  • inorganic particles having a specific surface area (measured by a BET analysis) of 10 m 2 /g or more may be preferably used.
  • acceptive compounds may be included in the undercoat layer.
  • Any acceptive compound may be used in the undercoat layer, and examples thereof include electron transporting substances such as quinone compounds such as chloranil and bromanil, tetracyanoquinodimethane compounds, fluorenone compounds such as 2,4,7-trinitrofluorenone and 2,4,5,7-tetranitro-9-fluorenone, oxadiazole compounds such as 2-(4-biphenyl)-5-(4-t-butylphenyl)-1,3,4-oxadiazole, 2,5-bis(4-naphthyl)-1,3,4-oxadiazole, and 2,5-bis(4-diethylaminophenyl)-1,3,4-oxadiazole, xanthone compounds, thiophene compounds and diphenoquinone compounds such as 3,3′2,5,5′-tetra-t-butyldiphenoquinone.
  • compounds having an anthraquinone structure may be preferably used.
  • the acceptive compound further include those having an anthraquinone structure such as hydroxyanthraquinone compounds, aminoanthraquinone compounds, and aminohydroxyanthraquinone compounds, and specific examples thereof include anthraquinone, alizarin, quinizarin, anthrarufin, and purpurin.
  • the content of the acceptive compound may be determined as appropriate. In embodiments, it may be preferably in the range of 0.01% by mass to 20% by mass, and more preferably in the range of 0.05% by mass to 10% by mass, with respect to the content of the inorganic particles.
  • the acceptor compound may simply be added at the time of application of the undercoat layer 4 , or may be previously attached to the surface of the inorganic particles.
  • Examples of the method of attaching the acceptor compound to the surface of the inorganic particles include a dry method and a wet method.
  • the acceptor compound is added dropwise to the inorganic particles or sprayed thereto together with dry air or nitrogen gas, either directly or in the form of a solution in which the acceptor compound is dissolved in an organic solvent, while the inorganic particles are stirred with a mixer or the like having a high shearing force.
  • the addition or spraying may be preferably carried out at a temperature lower than the boiling point of the solvent.
  • the inorganic particles may further be subjected to baking at a temperature of 100° C. or higher. The baking may be carried out as appropriate at a temperature and timing.
  • the inorganic particles are dispersed in a solvent by means of stirring, ultrasonic wave, a sand mill, an attritor, a ball mill or the like, then the acceptor compound is added and the mixture is further stirred or dispersed, thereafter the solvent is removed, and thereby the particles are surface-treated.
  • the solvent is removed by filtration or distillation.
  • the particles may be subjected to baking at a temperature of 100° C. or higher. The baking can be carried out at any temperature and timing.
  • the moisture contained in the inorganic particles may be removed prior to adding the surface treatment agent. The moisture can be removed by, for example, stirring and heating the particles in the solvent used for the surface treatment, or by azeotropic removal with the solvent.
  • the inorganic particles may be subjected to a surface treatment prior to the addition of the acceptor compound.
  • the surface treatment agent may be selected from known materials. Examples thereof include silane coupling agents, titanate coupling agents, aluminum coupling agents and surfactants. Among these, silane coupling agents may be preferably used, and silane coupling agents having an amino group may be more preferably used.
  • the silane coupling agents having amino groups may be any compounds. Specific examples thereof include ⁇ -aminopropyltriethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropyltrimethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropylmethydilmethoxysilane, and N,N-bis( ⁇ -hydroxyethyl)- ⁇ -aminopropyltriethoxysilane, but are not limited thereto.
  • the silane coupling agent may be used singly or in combination of two or more kinds thereof.
  • Examples of the silane coupling agents which can be used in combination with the silane coupling agents having an amino group include vinyltrimethoxysilane, ⁇ -methacryloxypropyl-tris-( ⁇ -methoxyethoxy)silane, ⁇ -(3,4-epoxycyclohexyl)ethyltrimethoxysilane, ⁇ -glycidoxypropyltrimethoxysilane, vinyltriacetoxysilane, ⁇ -mercaptopropyltrimethoxysilane, ⁇ -aminopropyltriethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropyltrimethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropylmethyldimethoxysilane, N,N-bis( ⁇ -hydroxyethyl)- ⁇ -
  • the surface treatment method may be any known method, and may be preferably a dry method or a wet method. Addition of an acceptor and a surface treatment using a coupling agent or the like may be carried out simultaneously.
  • the content of the silane coupling agent contained in the undercoat layer 4 may be determined as appropriate. In embodiments, it may be preferably 0.5% by mass to 10% by mass with respect to the content of the inorganic particles in the undercoat layer 4 .
  • any known resin may be used as the binding resin contained in the undercoat layer 4 .
  • known polymer resin compounds such as acetal resins such as polyvinyl butyral, polyvinyl alcohol resins, casein, polyamide resins, cellulose resins, gelatin, polyurethane resins, polyester resins, methacrylic resins, acrylic resins, polyvinyl chloride resins, polyvinyl acetate resins, vinyl chloride-vinyl acetate-maleic anhydride resins, silicone resins, silicone-alkyd resins, phenolic resins, phenol-formaldehyde resins, melamine resins and urethane resins; charge transporting resins having charge transporting groups; and conductive resins such as polyaniline.
  • acetal resins such as polyvinyl butyral, polyvinyl alcohol resins, casein, polyamide resins, cellulose resins, gelatin, polyurethane resins, polyester resins, methacrylic resins, acrylic resins
  • Preferable examples thereof include resins which are insoluble in the coating solvent for the upper layer, and more preferable examples thereof include phenolic resins, phenol-formaldehyde resins, melamine resins, urethane resins, and epoxy resins. When these resins are used in combination of two or more kinds, the mixing ratio can be appropriately determined according to the circumstances.
  • the ratio of the content of the metal oxide imparted with the properties as an acceptor to the content of the binder resin, or the ratio of the content of the inorganic particles to the content of the binder resin, in the coating liquid for forming the undercoat layer, may be appropriately determined.
  • additives may be used for the undercoat layer 4 .
  • the additives include known materials such as electron transporting pigments such as polycyclic condensed electron transporting pigments or azo electron transporting pigments, zirconium chelate compounds, titanium chelate compounds, aluminum chelate compounds, titanium alkoxide compounds, organic titanium compounds, and silane coupling agents. Silane coupling agents, which are used for surface treatment of metal oxides, may also be added to the coating liquid as additives.
  • silane coupling agents include vinyltrimethoxysilane, ⁇ -methacryloxypropyl-tris( ⁇ -methoxyethoxy)silane, ⁇ -(3,4-epoxycyclohexyl)ethyltrimethoxysilane, ⁇ -glycidoxypropyltrimethoxysilane, vinyltriacetoxysilane, ⁇ -mercaptopropyltrimethoxysilane, ⁇ -aminopropyltriethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropyltrimethoxysilane, N- ⁇ -(aminoethyl)- ⁇ -aminopropylmethyldimethoxysilane, N,N-bis( ⁇ -hydroxyethyl)- ⁇ -aminopropyltriethoxysilane, and ⁇ -chloropropyltrimethoxysilane.
  • zirconium chelate compounds examples include zirconium butoxide, zirconium ethyl acetoacetate, zirconium triethanolamine, acetylacetonate zirconium butoxide, ethyl acetoacetate zirconium butoxide, zirconium acetate, zirconium oxalate, zirconium lactate, zirconium phosphonate, zirconium octanoate, zirconium naphthenate, zirconium laurate, zirconium stearate, isostearic acid zirconium, methacrylate zirconium butoxide, stearate zirconium butoxide, and isostearate zirconium butoxide.
  • titanium chelate compounds examples include tetraisopropyl titanate, tetranormalbutyl titanate, butyl titanate dimer, tetra(2-ethylhexyl)titanate, titanium acetyl acetonate, polytitaniumacetyl acetonate, titanium octylene glycolate, titanium lactate ammonium salt, titanium lactate, titanium lactate ethyl ester, titanium triethanol aminato, and polyhydroxy titanium stearate.
  • aluminum chelate compounds examples include aluminum isopropylate, monobutoxy aluminum diisopropylate, aluminum butylate, ethylacetoacetate aluminum diisopropylate, and aluminum tris(ethylacetoacetate).
  • These compounds may be used alone, or as a mixture or a polycondensate of two or more kinds thereof.
  • the solvent for preparing the coating liquid for forming the undercoat layer may appropriately be selected from known organic solvents such as alcohol solvents, aromatic solvents, hydrocarbon halide solvents, ketone solvents, ketone alcohol solvents, ether solvents, and ester solvents.
  • Examples thereof include common organic solvents such as methanol, ethanol, n-propanol, iso-propanol, n-butanol, benzyl alcohol, methyl cellosolve, ethyl cellosolve, acetone, methyl ethyl ketone, cyclohexanone, methyl acetate, ethyl acetate, n-butyl acetate, dioxane, tetrahydrofuran, methylene chloride, chloroform, chlorobenzene, and toluene.
  • common organic solvents such as methanol, ethanol, n-propanol, iso-propanol, n-butanol, benzyl alcohol, methyl cellosolve, ethyl cellosolve, acetone, methyl ethyl ketone, cyclohexanone, methyl acetate, ethyl acetate, n-buty
  • solvents used for dispersing may be used alone or as a mixture of two or more kinds thereof. When they are mixed, any mixed solvents which can solve a binder resin can be used.
  • Any known device such as a roll mill, a ball mill, a vibration ball mill, an attritor, a sand mill, a colloid mill, or a paint shaker may be used to perform the dispersion.
  • known methods such as blade coating, wire bar coating, spray coating, dip coating, bead coating, air knife coating, curtain coating or the like may be used.
  • the undercoat layer 4 may be formed on the substrate 1 using the thus-obtained coating liquid.
  • the Vickers hardness of the undercoat layer 4 may be preferably 35 or more.
  • the thickness of the undercoat layer 4 may be arbitrarily determined. In embodiments, it may be preferably 15 ⁇ m or more, and more preferably from 15 ⁇ m to 50 ⁇ m.
  • the surface roughness of the undercoat layer 4 may be adjusted in the range of from [1/(4n)] ⁇ to 1 ⁇ 2 ⁇ , where ⁇ represents the wavelength of the laser for exposure and n represents a refractive index of the upper layer, in view of suppressing formation of a moire image.
  • Particles of a resin or the like may be added to the undercoat layer for adjusting the surface roughness.
  • the resin particles include silicone resin particles and particles of crosslinked polymethyl methacrylate resin.
  • the undercoat layer may be subjected to polishing for adjusting the surface roughness thereof.
  • polishing method include buffing, a sandblast treatment, a wet honing, and a grinding treatment.
  • the undercoat layer may be obtained by drying the applied coating, which is usually carried out at a temperature at which the solvent evaporates to form a film.
  • the charge generating layer 2 A is a layer having at least a charge generating material and a binder resin.
  • Examples of the charge generating material include azo pigments such as bis-azo pigments and tris-azo pigments, condensed aromatic pigments such as dibromoanthanthrone, perylene pigments, pyrrolopyrrole pigments, phthalocyanine pigments, zinc oxide, and trigonal selenium.
  • metal- or non-metal-phthalocyanine pigments may be favorably used in exposure with near-infrared laser light. Hydroxygallium phthalocyanine disclosed in JP-A Nos. 5-263007 and 5-279591, chlorogallium phthalocyanine disclosed in JP-A No. 5-98181, dichlorotin phthalocyanine disclosed in JP-A Nos.
  • the charge generating material may be preferably an inorganic pigment when an exposure light source with a wavelength of from 380 nm to 500 nm is used, and may be preferably a non-metal phthalcyanine pigment when an exposure light source with a wavelength of from 700 nm to 800 nm is used.
  • Hydroxygallium phthalozyanine pigments having a maximum peak wavelength in a range of from 810 nm to 839 nm in a spectral absorption spectrum of a wavelength region of from 600 nm to 900 nm may be preferably used as the charge generating material.
  • This hydroxygallium phthalocyanine pigments differ from conventional V-type hydroxygallium phthalocyanine pigments in that the maximum peak wavelength of a spectral absorption spectrum thereof is sifted to be shorter than that of conventional V-type hydroxygallium phthalocyanine pigments.
  • the hydroxygallium phthalozyanine pigment having a maximum peak wavelength in a range of from 810 nm to 839 nm may preferably have an average particle size and a BET specific surface area in a certain range.
  • the average particle diameter may be preferably 0.20 ⁇ m or less, and more preferably from 0.01 ⁇ m to 0.15 ⁇ m
  • the BET specific surface area may be preferably 45 m 2 /g or more, and more preferably 50 m 2 /g or more, and further preferably from 55 m 2 /g to 120 m 2 /g.
  • the average particle size here is a volume average particle size (d50 average particle size) measured by a laser diffraction/scattering type particle size distribution tester (trade name: LA-700, manufactured by Horiba, Ltd.), and the BET specific surface area is measured by a nitrogen substitution method using a BET specific surface area analyzer (trade name: FLOWSORB II 2300, manufactured by Shimadzu Corporation).
  • the maximum particle size (maximum primary particle size) of the hydroxygallium phthalozyanine pigment may be preferably 1.2 ⁇ m or less, more preferably 1.0 ⁇ m or less, and further preferably 0.3 ⁇ m or less.
  • the hydroxygallium phthalocyanine pigment may preferably have an average particle size of 0.2 ⁇ m or less, a maximum particle size of 1.2 ⁇ m or less, and a BET specific surface area of 45 m 2 /g or more.
  • the hydroxygallium phthalocyanine pigment may preferably have diffraction peaks at 7.5°, 9.9°, 12.5°, 16.3°, 18.6°, 25.1° and 28.3° of Bragg angles (2 ⁇ 0.2°) in an X-ray diffraction spectrum obtained using CuK ⁇ characteristic X rays.
  • the hydroxygallium phthalocyanine pigment may preferably have a thermogravimetric reduction rate when a temperature is increased from 25° C. to 400° C. of from 2.0% to 4.0%, and more preferably from 2.5% to 3.8%.
  • the binder resin used in the charge generating layer 2 A may be selected from a wide range of insulating resins, and also from organic photoconductive polymers such as poly-N-vinyl carbazole, polyvinyl anthracene, polyvinyl pyrene, and polysilane.
  • the binder resin include polyvinyl butyral resins, polyarylate resins (polycondensates of bisphenols and aromatic divalent carboxylic acid, or the like), polycarbonate resins, polyester resins, phenoxy resins, vinyl chloride-vinyl acetate copolymers, polyamide resins, acrylic resins, polyacrylamide resins, polyvinyl pyridine resins, cellulose resins, urethane resins, epoxy resins, casein, polyvinyl alcohol resins, and polyvinyl pyrrolidone resins. These binder resins may be used alone or in combination of two or more kinds.
  • the mixing ratio between the charge generating material and the binder resin is preferably in the range of from 10:1 to 1:10 by weight ratio.
  • the term “insulating” herein means that the resin has a volume resistivity of 10 13 ⁇ m or more.
  • the charge generating layer 2 A may be formed by, for example, using a coating liquid in which the charge generating material and the binder resin are dispersed in a solvent.
  • solvent used for the dispersing examples include methanol, ethanol, n-propanol, n-butanol, benzyl alcohol, methyl cellosolve, ethyl cellosolve, acetone, methyl ethyl ketone, cyclohexanone, methyl acetate, n-butyl acetate, dioxane, tetrahydrofuran, methylene chloride, chloroform, chlorobenzene and toluene. These solvents may be used alone or in combination of two or more kinds.
  • the method of dispersing the charge generating material and the binder resin in a solvent may be any ordinary method such as ball mill dispersing, attritor dispersing or sand mill dispersing.
  • the average particle diameter of the charge generating material to be dispersed may be preferably 0.5 ⁇ m or less, more preferably 0.3 ⁇ m or less, and further preferably 0.15 ⁇ m or less.
  • the method of forming the charge generating layer 2 A may be any conventional method such as blade coating, Meyer bar coating, spray coating, dip coating, bead coating, air knife coating, or curtain coating.
  • the film thickness of the charge generating layer 2 obtained by this method may be preferably from 0.1 ⁇ m to 5.0 ⁇ m, and more preferably from 0.2 ⁇ m to 2.0 ⁇ m.
  • the charge transport layer 2 B may preferably contain a charge transporting material and a binder resin, or may preferably contain a polymeric charge transporting material.
  • Examples of the charge transporting material include: electron transporting compounds such as quinone compounds such as p-benzoquinone, chloranil, bromanil and anthraquinone, tetracyanoquinodimethane compounds, fluorenone compounds such as 2,4,7-trinitro fluorenone, xanthone compounds, benzophenone compounds, cyanovinyl compounds, and ethylene compounds; and hole transporting compounds such as triarylamine compounds, benzidine compounds, arylalkane compounds, aryl substituted ethylene compounds, stilbene compounds, anthracene compounds, and hydrazone compounds. These charge transporting materials may be used alone or in combination of two or more kinds thereof, and are not limited thereto.
  • electron transporting compounds such as quinone compounds such as p-benzoquinone, chloranil, bromanil and anthraquinone, tetracyanoquinodimethane compounds, fluorenone compounds such as 2,4,7-trinitro fluorenone, x
  • the charge transporting material may be preferably a triaryl amine derivative represented by the following Formula (a-1) and a benzidine derivative represented by the following Formula (a-2), from the viewpoint of charge mobility.
  • R 8 represents a hydrogen atom or a methyl group
  • n represents 1 or 2
  • Ar 6 and Ar 7 each independently represent a substituted or unsubstituted aryl group, —C 6 H 4 —C(R 9 ) ⁇ C(R 10 )(R 11 ), or —C 6 H 4 —CH ⁇ CH—CH ⁇ C(R 12 )(R 13 ), wherein R 9 through R 13 each independently represent a hydrogen atom, a substituted or unsubstituted alkyl group, or a substituted or unsubstituted aryl group.
  • the substituent is a halogen atom, an alkyl group having 1 to 5 carbon atoms, an alkoxy group having 1 to 5 carbon atoms, or an amino group having an alkyl group having 1 to 3 carbon atoms as a substituent.
  • R 14 and R 14′ may be the same or different from each other, and each independently represent a hydrogen atom, a halogen atom, an alkyl group having 1 to 5 carbon atoms, or an alkoxy group having 1 to 5 carbon atoms;
  • R 15 , R 15′ , R 16 and R 16′ may be the same or different from each other, and each independently represent a hydrogen atom, a halogen atom, an alkyl group having 1 to 5 carbon atoms, an alkoxy group having 1 to 5 carbon atoms, an amino group having an alkyl group having 1 to 2 carbon atoms as a substituent, a substituted or unsubstituted aryl group, —C(R 17 ) ⁇ C(R 18 )(R 19 ), or —CH ⁇ CH—CH ⁇ C(R 20 )(R 21 ), wherein R 17 through R 21 each independently represent a hydrogen atom, a substituted or unsubstituted alkyl group, or a substitute
  • triarylamine derivatives represented by Formula (a-1) and the benzidine derivatives represented by Formula (a-2) triarylamine derivatives having —C 6 H 4 —CH ⁇ CH—CH ⁇ C(R 12 )(R 13 ) and benzidine derivatives having —CH ⁇ CH—CH ⁇ C(R 20 )(R 21 ) may be preferable.
  • binder resin used in the charge transport layer 2 B examples include polycarbonate resins, polyester resins, polyarylate resins, methacrylic resins, acrylic resins, polyvinyl chloride resins, polyvinylidene chloride resins, polystyrene resins, polyvinyl acetate resins, styrene-butadiene copolymers, vinylidene chloride-acrylonitrile copolymers, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-maleic anhydride copolymers, silicone resins, silicone alkyd resins, phenol-formaldehyde resins, styrene-alkyd resins, poly-N-vinyl carbazole, and polysilane.
  • polymeric charge transporting materials such as the polyester polymer charge transporting materials disclosed in JP-A Nos. 8-176293 and 8-208820 may also be used as the binder resin. These binder resins may be used alone or in combination of two or more kinds.
  • the mixing ratio between the charge transporting material and the binder resin is preferably from 10:1 to 1:5 by weight ratio.
  • the binder resin is not particularly limited. In embodiments, it may preferably include at least one selected from a polycarbonate resin having a viscosity-average molecular weight of from 50,000 to 80,000 or a polyarylate resin having a viscosity-average molecular weight of from 50,000 to 80,000.
  • Polymeric charge transport material may also be used as the charge transporting material.
  • the polymeric charge transporting material known materials having charge transporting properties such as poly-N-vinyl carbazole and polysilane may be used.
  • polyester polymeric charge transporting materials disclosed in JP-A Nos. 8-176293 and 8-208820, having higher charge transporting properties than that of other species, may be preferably used.
  • the charge transporting polymer material forms a film by itself, but may also be mixed with the above-described binder resin to form a film.
  • the charge transport layer 2 B may be formed using the coating liquid containing the component materials explained above.
  • the solvent used for the coating liquid for forming the charge transport layer include ordinary organic solvents such as aromatic hydrocarbons such as benzene, toluene, xylene and chlorobenzene; ketones such as acetone and 2-butanone; aliphatic hydrocarbon halides such as methylene chloride, chloroform and ethylene chloride; and cyclic or straight-chained ethers such as tetrahydrofuran and ethyl ether. These solvents may be used alone or in combination of two or more kinds.
  • the method for dispersing the component materials known methods may be used.
  • the method for applying the coating liquid for forming the charge transport layer onto the charge generating layer 2 ordinary methods such as blade coating, Meyer bar coating, spray coating, dip coating, bead coating, air knife coating and curtain coating may be used.
  • the film thickness of the charge transport layer 2 B may be preferably from 5 ⁇ m to 50 ⁇ m, and more preferably from 10 ⁇ m to 30 ⁇ m.
  • the protective layer 5 is an overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment.
  • the protective layer 5 that is the overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment contains at least:
  • the ratio of fluorine atom present in the outermost surface of the overcoat layer as measured with energy dispersive X-ray analysis (EDS) is from approximately 1.0% by mass to approximately 20.0% by mass.
  • the protective layer 5 that is the overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment contains at least the (A) cross-linked component that is obtained by cross-linking of at least one selected from a guanamine compound or a melamine compound and a charge-transporting material having at least one substituent group selected from —OH, —OCH 3 , —NH 2 , —SH, or —COOH (hereinafter referred to as a “specific charge-transporting material” in some cases).
  • the ratio of the sum of the content of the guanamine compound and the content of the melamine compound to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles and the content of the fluoro-alkyl group-containing copolymer may be preferably from approximately 0.1% by mass to approximately 20% by mass, and the ratio of the content of the specific charge-transporting material to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles and the content of the fluoro-alkyl group-containing copolymer may be preferably from approximately 80% by mass to approximately 99.9% by mass.
  • the guanamime compound is a compound having a guanamine skeleton (structure), and examples thereof include acetoguanamine, benzoguanamine, formguanamine, steroguanamine, spiroguanamine, and cyclohexylguanamine.
  • the guanamine compound may be preferably at least one of the compound represented by the following Formula (A) or a polymer thereof.
  • the polymer herein refers to an oligomer which is obtained by polymerizing the compound represented by Formula (A) as a structural unit and has a polymerization degree of, for example, from 2 to 200, preferably from 2 to 100.
  • the compound represented by Formula (A) may be used alone or as a mixture of two or more kinds thereof.
  • R 1 represents a linear or branched alkyl group having 1 to 10 carbon atoms, a substituted or unsubstituted phenyl group having 6 to 10 carbon atoms, or a substituted or unsubstituted alicyclic hydrocarbon group having 4 to 10 carbon atoms
  • R 2 through R 5 each independently represent a hydrogen atom, —CH 2 —OH or —CH 2 —O—R 6 wherein R 6 represents a hydrogen atom or a linear or branched alkyl group having 1 to 10 carbon atoms.
  • the alkyl group represented by R 1 has 1 to 10 carbon atoms, preferably has 1 to 8 carbon atoms, and more preferably has 1 to 5 carbon atoms.
  • the alkyl group may be either linear or branched.
  • the phenyl group represented by R 1 has 6 to 10 carbon atoms, and preferably has 6 to 8 carbon atoms.
  • substituent that may substitute the phenyl group include a methyl group, an ethyl group, and a propyl group.
  • the alicyclic hydrocarbon group represented by R 1 has 4 to 10 carbon atoms, and may preferably has 5 to 8 carbon atoms.
  • substituent that may substitute the alicyclic hydrocarbon group include a methyl group, an ethyl group, and a propyl group.
  • the alkyl group represented by R 6 in “—CH 2 —O—R 6 ” represented by R 2 through R 5 has 1 to 10 carbon atoms, preferably has 1 to 8 carbon atoms, and more preferably has 1 to 6 carbon atoms.
  • the alkyl group may be either linear or branched.
  • Preferable examples of the alkyl group represented by R 6 include a methyl group, an ethyl group, and a butyl group.
  • the compound represented by Formula (A) may be preferably a compound in which R 1 represents a substituted or unsubstituted phenyl group having 6 to 10 carbon atoms, and R 2 through R 5 each independently represent —CH 2 —O—R 6 .
  • R 6 may be preferably selected from a methyl group or an n-butyl group.
  • the compound represented by Formula (A) may be synthesized from, for example, guanamine and formaldehyde by a known method such as that described on page 430 of Jikken Kagaku Koza, Fourth edition, Vol. 28, the disclosure of which is incorporated by reference herein.
  • Examples of commercial products of the compound represented by Formula (A) include SUPER BECKAMIN (R) L-148-55, SUPER BECKAMIN (R) 13-535, SUPER BECKAMIN (R) L-145-60 and SUPER BECKAMIN (R) TD-126 (all trade names, manufactured by DIC Inc.), and NIKALACK BL-60 and NIKALACK BX-4000 (all trade names, manufactured by Nippon Carbide Industries Co., Inc.).
  • the compound represented by Formula (A) (including a polymer thereof) obtained by synthesizing or purchasing may then be dissolved in an appropriate solvent such as toluene, xylene or ethyl acetate, and washed with distilled water or ion exchanged water, or may be treated with an ion exchange resin.
  • an appropriate solvent such as toluene, xylene or ethyl acetate
  • the melamine compound is a compound having a melamine skeleton (structure) and may be preferably at least one of the compound represented by the following Formula (B) and a polymer thereof.
  • the polymer here refers to an oligomer which is obtained by polymerizing the compound represented by Formula (B) as a structural unit and has a polymerization degree of, for example, from 2 to 200, preferably from 2 to 100.
  • the compound represented by Formula (B) may be used alone or as a mixture of two or more kinds thereof, or may be used in combination with the compound represented by Formula (A) or a polymer thereof.
  • R 7 through R 12 each independently represent a hydrogen atom, —CH 2 —OH or —CH 2 —O—R 13 wherein R 13 represents a linear or branched alkyl group having 1 to 5 carbon atoms.
  • R 13 represents a linear or branched alkyl group having 1 to 5 carbon atoms. Examples of the alkyl group include a methyl group, an ethyl group and a butyl group.
  • the compound represented by Formula (B) may be synthesized from, for example, melamine and formaldehyde by a known method such as that described on page 430 of Jikken Kagaku Koza, Fourth edition, Vol. 28.
  • Examples of commercial products of the compound represented by Formula (B) include SUPER MELAMI No. 90 (trade name, manufactured by NOF Corporation), SUPER BECKAMIN (R) TD-139-60 (trade name, manufactured by DIC Inc.), UBAN 2020 (trade name, manufactured by Mitsui Chemicals, Inc.), SUMITEX RESIN M-3 (trade name, manufactured by Sumitomo Chemical Co., Ltd.) and NIKALACK MW-30 (trade name, manufactured by Nippon Carbide Industries Co., Inc.).
  • the specific charge transporting material has at least one substituent selected from the group consisting of —OH, —OCH 3 , —NH 2 , —SH, or —COOH, which may be referred to as “specific reactive functional groups”.
  • the specific charge transporting material particularly preferably has at least two (or even more preferably three) substituents selected from the specific reactive functional groups.
  • F H represents an organic group derived from a compound having a hole transporting ability
  • R 14 and R 15 each independently represent a linear or branched alkylene group having 1 to 5 carbon atoms
  • n1 represents 0 or 1
  • n2 represents an integer of 1 to 4
  • n3 represents 0 or 1
  • X represents an oxygen atom, NH, or a sulfur atom
  • Y represents —OH, —OCH 3 , —NH 2 , —SH, or —COOH (namely, one of the specific reactive functional groups).
  • the compound having a hole transporting ability from which the organic group represented by F H is derived is preferably an arylamine derivative.
  • the arylamine derivative include triphenylamine derivatives and tetraphenylbenzidine derivatives.
  • the compound represented by Formula (I) may be preferably the compound represented by the following Formula (II).
  • Ar 1 through Ar 4 may be the same or different from each other and each independently represent a substituted or unsubstituted aryl group;
  • Ar 5 represents a substituted or unsubstituted aryl group or a substituted or unsubstituted arylene group;
  • D represents —(—R 1 —X) n1 (R 2 ) n3 —Y;
  • c represents 0 or 1;
  • k represents 0 or 1; the total number of D is 1 to 4;
  • R 1 and R 2 each independently represent a linear or branched alkylene group having 1 to 5 carbon atoms;
  • n1 represents 0 or 1;
  • n3 represents 0 or 1;
  • X represents an oxygen atom, NH, or a sulfur atom; and
  • Y represents —OH, —OCH 3 , —NH 2 , —SH, or —COOH.
  • R 1 and R 2 each independently represent a linear or branched alkylene group having 1 to 5 carbon atoms, n1 is preferably 1, X is preferably an oxygen atom, and Y is preferably a hydroxyl group.
  • n2 in Formula (I) corresponds to n2 in Formula (I), which is preferably from 2 to 4 and more preferably from 3 to 4.
  • a compound represented by Formula (I) or (II) preferably has from 2 to 4, more preferably has from 3 to 4, of the specific reactive functional groups per molecule.
  • Ar 1 through Ar 4 are preferably represented by any one selected from the formulae (1) through (7).
  • the formulae (1) through (7) are shown with “-(D) c ” which may be linked to each of Ar 1 through Ar 4 .
  • R 9 represents a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, a phenyl groups having an alkyl group having 1 to 4 carbon atoms or an alkoxy group having 1 to 4 carbon atom as a substituent thereof, an unsubstituted phenyl group, or an aralkyl group having 7 to 10 carbon atoms;
  • R 10 through R 12 each independently represent a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a phenyl group having an alkoxy group having 1 to 4 carbon atoms as a substituent thereof, an unsubstituted phenyl group, an aralkyl group having 7 to 10 carbon atoms, or a halogen atom;
  • Ar represents a substituted or unsubstituted arylene group;
  • D and c are defined in the same manner as “D” and “c” in Formula (II); s represents
  • R 13 and R 14 each independently represent a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a phenyl group having an alkoxy group having 1 to 4 carbon atoms as a substituent thereof, an unsubstituted phenyl group, an aralkyl group having 7 to 10 carbon atoms, or a halogen atom; and t represents an integer of from 1 to 3.
  • Z′ preferably represents one selected from the following formulae (10) through (17).
  • R 15 and R 16 each independently represent a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a phenyl group having an alkoxy group having 1 to 4 carbon atoms as a substituent thereof, an unsubstituted phenyl group, an aralkyl group having 7 to 10 carbon atoms, or a halogen atom;
  • W represents a divalent group;
  • q and r each independently represent an integer of from 1 to 10; and t represents an integer of from 1 to 3.
  • W is preferably a divalent group represented by any one of the following formulae (18) through (26).
  • u represents an integer of from 0 to 3.
  • Ar 5 when k is 0, Ar 5 preferably corresponds to the aryl group represented by Ar 1 through Ar 4 in the formulae (1) through (7); and when k is 1, Ar 5 preferably corresponds to an arylene group obtained by removing a hydrogen atom from the aryl group represented by Ar 1 through Ar 4 in the formulae (1) through (7).
  • the protective layer 5 that is the overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment contains at least the (B) fluoro-resin particles.
  • the average primary particle diameter of the fluoro-resin particles may be preferably from 0.05 ⁇ m to 1 ⁇ m and is more preferably from 0.1 ⁇ m to 0.5 ⁇ m.
  • the average primary particle diameter of the fluoro-resin particles herein refers to a value measured by a method including dispersing the fluoro-resin particles in the same solvent as that of the dispersion liquid containing the fluoro-resin particles dispersed therein to obtain a measurement liquid and subjecting the measurement liquid to measurement of the average primary particle diameter of the fluoro-resin particles at a refractive index of 1.35 using a laser diffraction type particle size distribution measuring device LA-700 (trade name, manufactured by Horiba, Ltd.).
  • the content of the (B) fluoro-resin particles with respect to the total solid content of the protective layer 5 that is the overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment may be preferably from 1% by mass to 30% by mass, and more preferably from 2% by mass to 20% by mass.
  • the protective layer 5 that is the overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment contains at least the (C) fluoro-alkyl group-containing copolymer.
  • the (C) fluoro-alkyl group-containing copolymer is not specifically limited. In embodiments, it may be preferably a fluoro graft polymer having a repeating unit represented by the following Structural Formula (1) and a repeating unit represented by the following Structural Formula (2), and more preferably a resin synthesized by graft polymerization or the like using a macromonomer formed from an acrylic acid ester, a methacrylic acid ester and/or the like and perfluoroalkylethyl(meth)acrylate and/or perfluoroalkyl(meth)acrylate.
  • the expression of “(meth)acrylate” encompasses both of acrylate and methacrylate.
  • the weight-average molecular weight of the fluoro-alkyl group-containing copolymer may be preferably from 10,000 to 100,000, and more preferably from 30,000 to 100,000.
  • the ratio of the content of the repeating unit represented by Structural Formula (1) to that of repeating unit represented by Structural Formula (2) may be preferably from 1:9 to 9:1, and may be more preferably from 3:7 to 7:3.
  • Examples of the alkyl group represented by R 1 , R 2 , R 3 or R 4 include a methyl group, an ethyl group, and a propyl group.
  • R 1 , R 2 , R 3 and R 4 may preferably each independently represent a hydrogen atom or a methyl group, and further preferably each independently represent a methyl group.
  • the (C) fluoro-alkyl group-containing copolymer may further include a repeating unit represented by the following Structural Formula (3).
  • the ratio of the sum of the content of the repeating unit represented by Structural Formula (1) and the content of the repeating unit represented by Structural Formula (2) to the content of the repeating unit represented by Structural Formula (3) (namely, 1+m:z) may be preferably from 10:0 to 7:3, and may be more preferably from 9:1 to 7:3.
  • R 5 and R 6 each independently represent a hydrogen atom or an alkyl group, and z represents an integer equal to or larger than 1.
  • R 5 and R 6 may preferably each independently represent a hydrogen atom, a methyl group, or an ethyl group, and further preferably each independently represent a methyl group.
  • the content of the (C) fluoro-alkyl group-containing copolymer in the protective layer 5 that is the overcoat layer of the electrophotographic photoreceptor of the first exemplary embodiment may be preferably 1% by mass to 10% by mass with respect to the content of (B) the fluoro-resin particles in the protective layer 5 .
  • the protective layer 5 may include, in combination with the cross-linked component formed from at least one selected from the guanamine compound or the melamine compound and the specific charge transporting material, other thermosetting resin such as a phenolic resin, a melamine resin, an urea resin, an alkyd resin, or a benzoguanamine resin.
  • other thermosetting resin such as a phenolic resin, a melamine resin, an urea resin, an alkyd resin, or a benzoguanamine resin.
  • a compound having more functional groups in one molecule such as a spiroacetal guanamine resin (for example, CTU-GUANAMINE (trade name, manufactured by Ajinomoto-Fine-Techno Co., Inc.)) may be copolymerized with the material to be incorporated in the cross-linked component.
  • CTU-GUANAMINE trade name, manufactured by Ajinomoto-Fine-Techno Co., Inc.
  • the protective layer 5 may further include a surfactant in view of suppressing surface defects such as repellency.
  • a surfactant include those having at least one of a fluorine atom, an alkylene oxide structure or a silicone structure.
  • the protective layer 5 may further include an antioxidant.
  • the antioxidants include hindered phenol antioxidants and hindered amine antioxidants, and known antioxidants such as organic sulfur antioxidant, phosphite antioxidants, dithiocarbamate antioxidants, thiourea antioxidants and benzimidazole antioxidants may also be used.
  • the content of the antioxidant may be preferably 20% by mass or less, and more preferably 10% by mass or less.
  • hindered phenol antioxidant examples include 2,6-di-t-butyl-4-methylphenol, 2,5-di-t-butylhydroquinone, N,N′-hexamethylene bis(3,5-di-t-butyl-4-hydroxyhydrocinnamide, 3,5-di-t-butyl-4-hydroxy-benzylphosphonate-diethylester, 2,4-bis[(octylthio)methyl]-o-cresol, 2,6-di-t-butyl-4-ethylphenol, 2,2′-methylenebis(4-methyl-6-t-butylphenol), 2,2′-methylenebis(4-ethyl-6-t-butylphenol), 4,4′-butylidenebis(3-methyl-6-t-butylphenol), 2,5-di-t-amylhydroquinone, 2-t-butyl-6-(3-butyl-2-hydroxy-5-methylbenzyl)-4-methylpheny
  • the protective layer 5 may include a curing catalyst for accelerating curing of the guanamine compound, melamine compound and/or the charge transporting material.
  • the curing catalyst may be preferably an acid catalyst.
  • the acid catalyst include aliphatic carboxylic acids such as acetic acid, chloroacetic acid, trichloroacetic acid, trifluoroacetic acid, oxalic acid, maleic acid, malonic acid and lactic acid; aromatic carboxylic acids such as benzoic acid, phthalic acid, terephthalic acid and trimellitic acid; and aliphatic or aromatic sulfonic acids such as methanesulfonic acid, dodecylsulfonic acid, benzenesulfonic acid, dodecylbenzenesulfonic acid, and naphthalenesulfonic acid.
  • sulfur-containing materials may be preferable.
  • the sulfur-containing material used as a curing catalyst may be preferably one that is acidic at normal temperature (for example, at 25° C.) or after heating, and may be more preferably at least one of organic sulfonic acids and derivatives thereof.
  • the presence of the catalyst in the protective layer 5 may be readily detected by energy dispersive X-ray spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS) or the like.
  • organic sulfonic acids and/or the derivatives thereof examples include p-toluenesulfonic acid, dinonylnaphthalenesulfonic acid (DNNSA), dinonylnaphthalenedisulfonic acid (DNNDSA), dodecylbenzenesulfonic acid and phenolsulfonic acid.
  • DNNSA dinonylnaphthalenesulfonic acid
  • DNNDSA dinonylnaphthalenedisulfonic acid
  • dodecylbenzenesulfonic acid and phenolsulfonic acid examples include p-toluenesulfonic acid, dinonylnaphthalenesulfonic acid (DNNSA), dinonylnaphthalenedisulfonic acid (DNNDSA), dodecylbenzenesulfonic acid and phenolsulfonic acid.
  • p-toluenesulfonic acid and dodecylbenzenesulfonic acid may be
  • a so-called heat latent catalyst that exhibits an increased degree of catalytic activity upon application of heat may also be used.
  • the heat latent catalyst examples include microcapsules formed by coating an organic sulfone compound or the like with a polymer in the form of particles; porous compounds such as zeolite to which an acid or the like is adsorbed; a heat latent protonic acid catalyst in which a protonic acid and/or a derivative thereof is blocked with a base; a compound obtained by esterifying a protonic acid and/or a derivative thereof with a primary or secondary alcohol; a compound obtained by blocking a protonic acid and/or a derivative thereof with a vinyl ether and/or a vinyl thioether; monoethyl amine complexes of boron trifluoride; and pyridine complexes of boron trifluoride.
  • Examples of the protonic acid of the heat latent protonic acid catalyst include sulfuric acid, hydrochloric acid, acetic acid, formic acid, nitric acid, phosphoric acid, sulfonic acid, monocarboxylic acid, polycarboxylic acids, propionic acid, oxalic acid, benzoic acid, acrylic acid, methacrylic acid, itaconic acid, phthalic acid, maleic acid, benzene sulfonic acid, o-, m- or p-toluenesulfonic acid, styrenesulfonic acid, dinonylnaphthalenesulfonic acid, dinonylnaphthalenedisulfonic acid, decylbenzenesulfonic acid, undecylbenzenesulfonic acid, tridecylbenzenesulfonic acid, tetradecylbenzenesulfonic acid and dodecylbenzenesulfonic acid.
  • Examples of the protonic acid derivative include neutralized alkali metal salts or alkali earth metal salts of protonic acids such as sulfonic acid and phosphoric acid, and polymer compounds in which a protonic acid skeleton is incorporated into a polymer chain (such as polyvinylsulfonic acid).
  • Examples of the base that blocks the protonic acid include amines.
  • Amines are classified into primary, secondary, and tertiary amines. Any of these amines may be herein used without particular limitation.
  • Examples of the primary amines include methylamine, ethylamine, propylamine, isopropylamine, n-butylamine, isobutylamine, t-butylamine, hexylamine, 2-ethylhexylamine, secondary butylamine, allylamine and methylhexylamine.
  • tertiary amines examples include trimethylamine, triethylamine, tri-n-propylamine, triisopropylamine, tri-n-butylamine, triisobutylamine, tri-t-butylamine, trihexylamine, tri(2-ethylhexyl)amine, N-methyl morpholine, N,N-dimethylallylamine, N-methyl diallylamine, triallylamine, N,N-dimethylallylamine, N,N,N,N′-tetramethyl-1,2-diaminoethane, N,N,N′,N′-tetramethyl-1,3-diaminopropane, N,N,N′,N′-tetraallyl-1,4-diaminobutane, N-methylpiperidine, pyridine, 4-ethylpyridine, N-propyldiallylamine, 3-dimethylaminopropanol, 2-ethyl
  • Examples of commercially available products of the catalyst include NACURE 2501 (toluenesulfonic acid dissociation, methanol/isopropanol solvent, pH: 6.0 to 7.2, dissociation temperature: 80° C.), NACURE 2107 (p-toluenesulfonic acid dissociation, isopropanol solvent, pH: 8.0 to 9.0, dissociation temperature: 90° C.), NACURE 2500 (p-toluenesulfonic acid dissociation, isopropanol solvent, pH: 6.0 to 7.0, dissociation temperature: 65° C.), NACURE 2530 (p-toluenesulfonic acid dissociation, methanol/isopropanol solvent, pH: 5.7 to 6.5, dissociation temperature: 65° C.), NACURE 2547 (p-toluenesulfonic acid dissociation, aqueous solution, pH: 8.0 to 9.0, dissociation temperature: 107° C.
  • These heat latent catalysts may be used alone or in combination of two or more kinds thereof.
  • the ratio of the content of the catalyst to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles and the content of the fluoro-alkyl group-containing copolymer may be preferably from approximately 0.1% by mass to approximately 10% by mass, and more preferably from approximately 0.1% by mass to approximately 5% by mass.
  • One exemplary embodiment of another aspect herein provided is a method of producing the photoreceptor according to the first aspect including forming the overcoat layer.
  • the method may include forming the protective layer 5 , that is the overcoat layer in the first exemplary embodiment of the first aspect, as follows.
  • an exemplary embodiment the method of producing the photoreceptor of the first exemplary embodiment of the first aspect may include at least: preparing the substrate 1 having one or more layers, the one or more layers being other than the overcoat layer having the outermost surface (namely, preparing the substrate 1 having the undercoat layer 4 , the charge-generating layer 2 A, and the charge-transporting layer 2 B, which are other than the protective layer 5 ); and forming the overcoat layer (protective layer 5 ) by applying a coating liquid on the substrate 1 and cross-linking components of the coating liquid applied on the substrate, the coating liquid containing at least one selected from a guanamine compound or a melamine compound and a charge-transporting material having at least one substituent group selected from —OH, —OCH 3 , —NH 2 , —SH, or —COOH (the specific charge-transporting material); fluoro-resin particles; a fluoro-alkyl group-containing copolymer; and a cyclic aliphatic
  • the coating liquid for forming the protective layer 5 having the structure explained above contains at least one of the guanamine compound or the melamine compound, at least one of the specific charge-transporting materials, the fluoro-resin particles, and the content of the fluoro-alkyl group-containing copolymer, details of which are explained above as the components of the protective layer 5 .
  • a solvent in the coating liquid may be either one kind solvent or a mixture of two or more kinds of solvents.
  • the solvent may preferably contain a cyclic aliphatic ketone compound. In embodiments, only one kind of the cyclic aliphatic ketone compound is used therefor.
  • the use of the cyclic aliphatic ketone compound may facilitate to have the fluoro-resin particles that are contained in the protective layer 5 serving as the overcoat layer expose on the outermost surface, so that the surface energy lowers and that a property of excellent cleaning ability may be exerted immediately after beginning of use of the photoreceptor.
  • the solvent used for forming the protective layer 5 as the overcoat layer may be preferably the cyclic aliphatic ketone compound such as cyclobutanone, cyclopentanone, cyclohexanone or cycloheptanone as described above.
  • another solvent may be used in combination with the cyclic aliphatic ketone compound, examples thereof including cyclic- or straight-chain-alcohols such as methanol, ethanol, propanol, butanol, and cyclopentanol; straight-chain-ketones such as acetone and methyl ethyl ketone; straight-chain-ethers such as tetrahydrofuran, dioxane, ethylene glycol and diethyl ether; and haloganated aliphatic hydrocarbon solvents such as methylene chloride, chloroform, and ethylene chloride.
  • cyclic- or straight-chain-alcohols such as methanol, ethanol, propanol, butanol, and cyclopentanol
  • straight-chain-ketones such as acetone and methyl ethyl ketone
  • straight-chain-ethers such as tetrahydrofuran, dioxane, ethylene glycol and dieth
  • the cyclic aliphatic ketone compound may be preferably that having a ring including 4 to 7 carbon atoms, and may be more preferably that having a ring including 5 or 6 carbon atoms.
  • the content of the solvent used for forming the protective layer 5 is not particularly limited. In embodiments, it may be from 0.5% by mass to 30% by mass, and may be preferably from 1% by mass to 20% by mass, with respective to 1% by mass of the guanamine compound or the melamine compound.
  • Examples of a method for applying the coating liquid for forming the protective layer as the overcoat layer include thrust up coating, ring coating, blade coating, Mayer bar coating, spray coating, dip coating, bead coating, air knife coating, curtain coating, and inkjet coating.
  • the coating liquid may be subjected to curing (cross-linking) by heating at a temperature of, for example, from 100° C. to 170° C., to provide the protective layer 5 .
  • a photoreceptor according to the second exemplary embodiment of the first aspect has, as shown in FIG. 2 , the undercoat layer 4 , the charge-generating layer 2 A, and the charge-transporting layer 2 B which are stacked on the substrate 1 in this order to form a layer configuration, and the charge-transporting layer 2 B serves as the overcoat layer.
  • the substrate 1 , the undercoat layer 4 , and the charge-generating layer 2 A in the second exemplary embodiment are similar to those of the first exemplary embodiment as shown in FIG. 1 .
  • the charge-transporting layer 2 B that serves as the overcoat layer in the photoreceptor according to the second exemplary embodiment of the first aspect, includes at least:
  • the ratio of fluorine atom present in the outermost surface of the overcoat layer as measured with energy dispersive X-ray analysis (EDS) is from approximately 1.0% by mass to approximately 20.0% by mass.
  • the components (A) to (C) that are described as those for the protective layer 5 in the first exemplary embodiment of the first aspect may be used as the component (A) to (C) in the charge-transporting layer 2 B of this exemplary embodiment as they are.
  • Examples of the component (D) that may be contained in the charge-transporting layer 2 B include, besides the component (D) that is described in the protective layer 5 in the first exemplary embodiment, various kinds of compositions that may be contained in the charge-transporting layer 2 B in the first exemplary embodiment.
  • the charge-transporting layer 2 B that serves as the overcoat layer in the second exemplary embodiment may be preferably formed in accordance with the method of forming the protective layer 5 that serves as the overcoat layer in the exemplary embodiment.
  • the method of producing the photoreceptor of the second exemplary embodiment of the first aspect may include at least: preparing the substrate 1 having one or more layers, the one or more layers being other than the overcoat layer having the outermost surface (namely, preparing the substrate 1 having the undercoat layer 4 , the charge-generating layer 2 A, and the like, which are other than the charge-transporting layer 2 B); and forming the overcoat layer (charge-transporting layer 2 B) by applying a coating liquid on the substrate 1 and cross-linking components of the coating liquid applied on the substrate, the coating liquid containing at least one selected from a guanamine compound or a melamine compound and a charge-transporting material having at least one substituent group selected from —OH, —OCH 3 , —NH 2 , —SH, or —COOH (the specific charge-transporting material); fluoro-resin particles; a fluoro-alkyl group-containing copolymer; and a cyclic aliphatic ketone compound,
  • the used amount of these solvents, the coating method of the coating liquid, and others are similar to those described in the method of forming the protective layer in the first exemplary embodiment.
  • a photoreceptor according to the third exemplary embodiment of the first aspect has, as shown in FIG. 3 , the undercoat layer 4 and the function-hybridized photosensitive layer 6 which are stacked on the substrate 1 in this order to form a layer configuration, and the function-hybridized photosensitive layer 6 serves as the overcoat layer.
  • the function-hybridized photosensitive layer 6 that serves as the overcoat layer in the photoreceptor according to the third exemplary embodiment of the first aspect, includes at least:
  • the ratio of fluorine atom present in the outermost surface of the overcoat layer as measured with energy dispersive X-ray analysis (EDS) is from approximately 1.0% by mass to approximately 20.0% by mass.
  • the components (A) to (C) that are described as those for the protective layer 5 in the first exemplary embodiment of the first aspect may be used as the component (A) to (C) in the function-hybridized photosensitive layer 6 of this exemplary embodiment as they are.
  • Examples of the component (D) that may be contained in the function-hybridized photosensitive layer 6 include, besides the component (D) that is described in the protective layer 5 in the first exemplary embodiment, various kinds of compositions that may be contained in the charge-generating layer 2 A or the charge-transporting layer 2 B in the first exemplary embodiment.
  • the function-hybridized photosensitive layer 6 that serves as the overcoat layer in the third exemplary embodiment may be preferably formed in accordance with the method of forming the protective layer 5 that serves as the overcoat layer in the exemplary embodiment.
  • the method of producing the photoreceptor of the third exemplary embodiment of the first aspect may include at least: preparing the substrate 1 having one or more layers, the one or more layers being other than the overcoat layer having the outermost surface (namely, preparing the substrate 1 having the undercoat layer 4 and the like, which are other than the function-hybridized photosensitive layer 6 ); and forming the overcoat layer (function-hybridized photosensitive layer 6 ) by applying a coating liquid on the substrate 1 and cross-linking components of the coating liquid applied on the substrate, the coating liquid containing at least one selected from a guanamine compound or a melamine compound and a charge-transporting material having at least one substituent group selected from —OH, —OCH 3 , —NH 2 , —SH, or —COOH (the specific charge-transporting material); fluoro-resin particles; a fluoro-alkyl group-containing copolymer; and a cyclic aliphatic ketone compound,
  • the used amount of these solvents, the coating method of the coating liquid, and others are similar to those described in the method of forming the protective layer in the first exemplary embodiment.
  • a process cartridge according to an exemplary embodiment of another aspect herein provided is not particularly limited as long as one exemplary embodiment of the electrophotographic photoreceptor of the first aspect is used therein.
  • the process cartridge may be preferably composed of the electrophotographic photoreceptor that serves as a latent image support and at least one selected from a charging unit, a development unit, or a cleaning unit, and freely attachable to and detachable from an image forming apparatus that transfers a toner image obtained by developing an electrostatic image on the surface of the latent image support onto a recording medium and forms an image on the recording medium.
  • an image forming apparatus is not particularly limited as long as one exemplary embodiment of the electrophotographic photoreceptor of the first aspect is used therein.
  • the image forming apparatus may be preferably composed of the electrophotographic photoreceptor, a charging unit that charges the electrophotographic photoreceptor, a latent image forming unit that forms an electrostatic latent image on a surface of the electrophotographic photoreceptor, a development unit that develops the electrostatic latent image formed on the surface of the electrophotographic photoreceptor with a toner and forms a toner image, and a transferring unit that transfers the toner image formed on the surface of the electrophotographic photoreceptor onto a recording medium.
  • the image forming apparatus may be a so-called tandem machine that possesses two or more photoreceptors corresponding to each of color toners.
  • all of the photoreceptors may be preferably the electrophotographic photoreceptor.
  • the toner image may be transferred in an intermediate transfer system in which an intermediate transfer member is used.
  • FIG. 4 is a schematic view showing an image forming apparatus according to an exemplary embodiment of one aspect of the invention.
  • the image forming apparatus 100 includes a process cartridge 300 equipped with an electrophotographic photoreceptor 7 , an exposure device 9 , a transfer device 40 , and an intermediate transfer member 50 .
  • the exposure device 9 is positioned such that the electrophotographic photoreceptor 7 is exposed to light through an opening of the process cartridge 300
  • the transfer device 40 is positioned opposite to the electrophotographic photoreceptor 7 via the intermediate transfer member 50
  • the intermediate transfer member 50 is positioned so as to be partially in contact with the electrophotographic photoreceptor 7 .
  • the process cartridge 300 integrally includes the electrophotographic photoreceptor 7 , the charging device 8 , a developing device 11 and a cleaning device 13 in a housing.
  • the cleaning device 13 has a cleaning blade 131 (cleaning member).
  • the cleaning blade 131 is positioned so as to be in contact with the surface of the electrophotographic photoreceptor 7 .
  • a fibrous member 132 (roll-shaped) that supplies a lubricant 14 to the surface of the electrophotographic photoreceptor 7 and a fibrous member 133 that assists cleaning (flat brush-shaped) are used in this exemplary embodiment, although these may be provided or may not be provided in this system.
  • a contact-type charging device employing a conductive or semiconductive charging roller, a charging brush, a charging film, a charging rubber blade, a charging tube, or the like may be used.
  • Known non contact-type charging devices such as a non contact-type roller charging device, scorotron or corotron charging devices utilizing corona discharge, or the like, may also be used.
  • a heating member may be provided around the electrophotographic photoreceptor 7 in order to increase the temperature of the electrophotographic photoreceptor 7 to reduce the relative temperature thereof.
  • Examples of the exposure device 9 include optical instruments which expose the surface of the electrophotographic photoreceptor 7 to light of a semiconductor laser, an LED, a liquid-crystal shutter light or the like in a pattern of desired image.
  • the wavelength of the light source to be used is in the range of the spectral sensitivity region of the electrophotographic photoreceptor.
  • As the semiconductor laser light near-infrared light having an oscillation wavelength in the vicinity of 780 nm is mainly used.
  • the wavelength of the light source is not limited to the above range, and lasers having an oscillation wavelength on the order of 600 nm and blue lasers having an oscillation wavelength in the vicinity of 400 nm to 450 nm may also be used.
  • Surface-emitting type laser light sources which are capable of multi-beam output may be also effective in forming a color image.
  • a common developing device that performs development by contacting or non-contacting a magnetic or non-magnetic one- or two-component developer may be used.
  • Such developing device is not particularly limited as long as it has above-described functions, and may be appropriately selected according to the preferred use. Examples thereof include known developing device that performs development by attaching one- or two-component developer to the electrophotographic photoreceptor 7 using a brush or a roller.
  • a toner to be used in the developing device 11 will be described below.
  • the toner particles used in the image forming apparatus of this exemplary embodiment may preferably have an average shape factor (ML 2 /A ⁇ /4 ⁇ 100, wherein ML represents a maximum length of a particle and A represents a projection area of the particle.) of 100 to 150, more preferably 105 to 145, and further preferably 110 to 140.
  • the volume-average particle diameter of the toner particles may be preferably 3 ⁇ m to 12 ⁇ m, and more preferably from 3.5 ⁇ m to 9 ⁇ m.
  • the method of producing the toner is not particularly limited.
  • the method include a kneading and pulverizing method in which a binder resin, a coloring agent, a releasing agent, and optionally a charge control agent or the like are mixed and kneaded, pulverized, and classified; a method of altering the shape of the particles obtained by the kneading and pulverizing method using mechanical shock or heat energy; an emulsion polymerization aggregation method in which a dispersion obtained by emulsifying and polymerizing a polymerizable monomer of a binder resin is mixed with a dispersion containing a coloring agent, a releasing agent, and optionally a charge control agent and/or other agents, then the mixture is subjected to aggregation, heating and coalescing to obtain toner particles; a suspension polymerization method in which a polymerizable monomer used to obtain a binder resin and a solution containing a coloring agent,
  • Known methods such as a method of producing toner particles having a core-shell structure in which aggregated particles are further attached to a core formed from the toner particles obtained by the above-described method, then heated and coalesced may also be used.
  • methods of producing a toner in an aqueous medium such as a suspension-polymerization method, an emulsion polymerization aggregation method, and a dissolution suspension method may be preferable, and an emulsion polymerization aggregation method may be further preferable from the viewpoint of controlling the shape and particle diameter distribution of the toner particles.
  • Toner mother particles may be preferably formed from a binder resin, a coloring agent and a releasing agent, and may optionally contain silica and/or a charge control agent.
  • binder resins used in the toner mother particles include monopolymers and copolymers of styrenes such as styrene and chlorostyrene, monoolefins such as ethylene, propylene, butylene and isoprene, vinyl esters such as vinyl acetate, vinyl propionate, vinyl benzoate, vinyl butyrate, ⁇ -methylene aliphatic monocarboxylic acid esters such as methyl acrylate, ethyl acrylate, butyl acrylate, dodecyl acrylate, octyl acrylate, phenyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and dodecyl methacrylate, vinyl ethers such as vinyl methyl ether, vinyl ethyl ether and vinyl butyl ether, and vinyl ketones such as vinyl methyl ketone, vinyl hexyl ketone and vinyl isopropen
  • binder resins examples include polystyrene, styrene-alkyl acrylate copolymer, styrene-alkyl methacrylate copolymer, styrene-acrylonitrile copolymer, styrene-butadiene copolymer, styrene-maleic anhydride copolymer, polyethylene, polypropylene and polyester resins.
  • Other examples include polyurethane, epoxy resins, silicone resins, polyamide, modified rosin and paraffin wax.
  • Examples of the typical coloring agents include magnetic powder such as magnetite and ferrite, carbon black, aniline blue, Calco Oil blue, chrome yellow, ultramarine blue, Du Pont oil red, quinoline yellow, methylene blue chloride, phthalocyanine blue, malachite green oxalate, lamp black, rose bengal, C. I. Pigment Red 48:1, C. I. Pigment Red 122, C. I. Pigment Red 57:1, C. I. Pigment Yellow 97, C. I. Pigment Yellow 17, C. I. Pigment Blue 15:1, and C. I. Pigment Blue 15:3.
  • magnetic powder such as magnetite and ferrite
  • carbon black aniline blue
  • Calco Oil blue chrome yellow
  • ultramarine blue Du Pont oil red
  • quinoline yellow methylene blue chloride
  • phthalocyanine blue malachite green oxalate
  • lamp black rose bengal
  • Examples of the typical releasing agents include low-molecular polyethylene, low-molecular polypropylene, Fischer-Tropsch wax, montan wax, carnauba wax, rice wax and candelilla wax.
  • Known agents such as azo metal-complex compounds, metal-complex compounds of salicylic acid, and resin-type charge control agents having polar groups can be used as the charge control agent.
  • toner particles are produced by a wet method, materials that do not readily dissolve in water may be preferably used.
  • the toner may be either a magnetic toner which contains a magnetic material or a non-magnetic toner which contains no magnetic material.
  • the toner particles used in the developing device 11 may be produced by mixing the toner mother particles and external additives using a Henschel mixer, a V blender or the like.
  • external additives may be added by a wet method.
  • the average particle diameter of the lubricant particles may be preferably in the range of from 0.1 ⁇ m to 10 ⁇ m, and those having the above-described chemical structure may be ground to form particles having such particle diameter.
  • the content of the particles in the toner may be preferably in the range of from 0.05% by mass to 2.0% by mass, more preferably 0.1% by mass to 1.5% by mass.
  • Inorganic particles, organic particles, composite particles in which inorganic particles are attached to organic particles, or the like may be added to the toner particles used in the developing device 11 .
  • Examples of the appropriate inorganic particles include various inorganic oxides, inorganic nitrides and inorganic borides such as silica, alumina, titania, zirconia, barium titanate, aluminum titanate, strontium titanate, magnesium titanate, zinc oxide, chromium oxide, cerium oxide, antimony oxide, tungsten oxide, tin oxide, tellurium oxide, manganese oxide, boron oxide, silicon carbide, boron carbide, titanium carbide, silicon nitride, titanium nitride and boron nitride.
  • inorganic oxides such as silica, alumina, titania, zirconia, barium titanate, aluminum titanate, strontium titanate, magnesium titanate, zinc oxide, chromium oxide, cerium oxide, antimony oxide, tungsten oxide, tin oxide, tellurium oxide, manganese oxide, boron oxide, silicon carbide, boron carbide, titanium carbide, silicon nitrid
  • the above-described inorganic particles may be treated with a titanium coupling agent or a silane coupling agent.
  • the titanium coupling agents include tetrabutyl titanate, tetraoctyl titanate, isopropyltriisostearoyl titanate, isopropyltridecylbenzenesulfonyl titanate and bis(dioctylpyrophosphate)oxyacetate titanate.
  • silane coupling agents examples include ⁇ -(2-aminoethyl)aminopropyltrimethoxysilane, ⁇ -(2-aminoethypaminopropylmethyldimethoxysilane, ⁇ -methacryloxypropyltrimethoxysilane, N- ⁇ -(N-vinylbenzylaminoethyl) ⁇ -aminopropyltrimethoxysilane hydrochloride, hexamethyldisilazane, methyltrimethoxysilane, butyltrimethoxysilane, isobutyltrimethoxysilane, hexyltrimethoxysilane, octyltrimethoxysilane, decyltrimethoxysilane, dodecyltrimethoxysilane, phenyltrimethoxysilane, o-methylphenyltrimethoxysilane and p-methylphenyltrimeth
  • These inorganic particles may be subjected to a hydrophobic treatment with silicone oil or a metal salt of higher fatty acids such stearic acid aluminum, stearic acid zinc and stearic acid calcium.
  • organic particles examples include styrene resin particles, styrene acrylic resin particles, polyester resin particles and urethane resin particles.
  • the number average particle diameter of these particles may be preferably from 5 nm to 1000 nm, more preferably from 5 nm to 800 nm, and further preferably from 5 nm to 700 nm.
  • the sum of the content of these particles and the content of the lubricant particles may be preferably 0.6% by mass or more.
  • a combination of small inorganic oxide particles having a primary diameter of 40 nm or less and inorganic oxide particles having a larger primary average diameter than the small inorganic oxide particles may be preferably used as the other inorganic oxides to be added to the toner particles.
  • These inorganic oxide particles may be formed from a known material, and in embodiments, a combination of silica particles and titanium oxide particles may be preferable.
  • the small inorganic particles may be subjected to a surface treatment. Addition of a carbonate such as calcium carbonate or magnesium carbonate or an inorganic mineral such as hydrotalcite may be also preferable.
  • Color toner particles for electrophotography are used in combination with carriers.
  • the carrier include iron powder, glass beads, ferrite powder, nickel powder and these powders coated with a resin.
  • the mixing ratio of the carrier may be determined in accordance with necessity.
  • Examples of the transfer device 40 include known transfer charging devices such as a contact type transfer charging devices using a belt, a roll, a film or a rubber blade, and that utilizing corona discharge such as a scorotron transfer charging device or a corotron transfer charging device.
  • transfer charging devices such as a contact type transfer charging devices using a belt, a roll, a film or a rubber blade, and that utilizing corona discharge such as a scorotron transfer charging device or a corotron transfer charging device.
  • intermediate transfer member 50 a belt to which semiconductivity is imparted and made of polyimide, polyamideimide, polycarbonate, polyarylate, polyester, rubber or the like (intermediate transfer belt) may be used.
  • the intermediate transfer member 50 may also be in the form of a drum.
  • the image forming apparatus 100 may further have, for example, a photodischarge device for charge-erasing the electrophotographic photoreceptor 7 .
  • FIG. 5 is a schematic cross-sectional view showing an image forming apparatus 120 according to another exemplary embodiment.
  • the image forming apparatus 120 is a tandem-type full-color image forming apparatus including four process cartridges 300 .
  • four process cartridges 300 are disposed in parallel with each other on the intermediate transfer member 50 , and one electrophotographic photoreceptor is used for each color.
  • the image forming apparatus 120 has a similar configuration to the image forming apparatus 100 , except that the apparatus is a tandem type.
  • the development apparatus may include a development roll as a developer retainer which moves (rotates) in a direction opposite to the direction (rotation direction) in which the electrophotographic photoreceptor moves.
  • the development roll has a cylindrical development sleeve for retaining the developer on the surface thereof, and the development apparatus may have a regulation member that regulates the amount of the developer to be supplied to the development sleeve.
  • the space between the development sleeve and the electrophotographic photoreceptor may be preferably from 200 ⁇ m to 600 ⁇ m, and more preferably from 300 ⁇ m to 500 ⁇ m.
  • the space between the development sleeve and the regulation blade, which is a regulation member that regulates the amount of the developer, may be preferably from 300 ⁇ m to 1000 ⁇ m, and more preferably from 400 ⁇ m to 750 ⁇ m.
  • An absolute value of moving velocity of the development roll surface may be preferably from 1.5 times to 2.5 times, more preferably from 1.7 times to 2.0 times, as large as an absolute value of the moving velocity of the electrophotographic photoreceptor surface.
  • the development apparatus may preferably include a developer retainer having a magnetic substance, and develops an electrostatic latent image with a two-component developer containing a magnetic carrier and a toner.
  • An electrophotographic photoreceptor is prepared in accordance with the following process.
  • 60 parts by mass of the surface-treated zinc oxide is mixed with 0.6 parts by mass of alizarin, 13.5 parts by mass of a curing agent (blocked isocyanate, trade name: SUMIDUR 3175, manufactured by Sumitomo-Bayer Urethane Co., Ltd.), 38 parts by mass of a solution prepared by dissolving 15 parts by mass of a butyral resin (trade name: S-LEC BM-1, manufactured by Sekisui Chemical Co., Ltd.) in 85 parts by mass of methyl ethyl ketone, and 25 parts by mass of methyl ethyl ketone are mixed and dispersed for 2 hours in a sand mill using glass beads having a diameter of 1 mm, thereby obtaining a dispersion.
  • a curing agent blocked isocyanate, trade name: SUMIDUR 3175, manufactured by Sumitomo-Bayer Urethane Co., Ltd.
  • an undercoat layer having a thickness of 19 ⁇ m is formed by applying the obtained coating liquid onto an aluminum substrate having a diameter of 30 mm by dip coating, and then drying to cure at a temperature of 170° C. for 40 minutes.
  • VMCH vinyl chloride-vinyl acetate copolymer resin
  • the coating liquid for forming a charge generating layer is applied onto the undercoat layer by dip coating, and dried at an ordinary temperature (25° C.) to form a charge generating layer having a film thickness of 0.2 ⁇ m.
  • a melamine resin and 95 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 220 parts by mass of cyclopentanone; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • Example 1 After that, 0.2 parts by mass of “NACURE 5225” (trade name, manufactured by King Industries, Inc.) that serves as a catalyst is added to the mixture so as to prepare a coating liquid for forming a protective layer.
  • the coating liquid is coated on the charge-transporting layer by using the thrust up coating technique and is cured by heating at 150° C. for 1 hour so as to obtain a thick protective layer having a thickness of 4 ⁇ m. In this way, an electrophotographic photoreceptor for Example 1 is prepared.
  • Streaky image density unevenness that is caused due to toner adhesion and depends on the cleaning ability, and fogging in the background that is caused due to wearing of the photosensitive layer are evaluated as follows.
  • a melamine resin and 95 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 210 parts by mass of cyclopentanone; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • Example 2 After that, 0.2 parts by mass of “NACURE 5225” (trade name, manufactured by King Industries, Inc.) that serves as a catalyst is added to the mixture so as to prepare a coating liquid for forming a protective layer. Then, an electrophotographic photoreceptor of Example 2 is produced in the substantially similar manner to that of Example 1, except that the coating liquid for forming a protective layer is replaced with that herein formed. Further, preparation of an electrophotographic apparatus and evaluation tests are performed in the substantially similar manner to those of Example 1, except that the electrophotographic photoreceptor of Example 2 is used in place of that of Example 1.
  • “NACURE 5225” trade name, manufactured by King Industries, Inc.
  • a melamine resin and 95 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 120 parts by mass of cyclopentanone; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • Example 3 an electrophotographic photoreceptor of Example 3 is produced in the substantially similar manner to that of Example 1, except that the coating liquid for forming a protective layer is replaced with that herein formed. Further, preparation of an electrophotographic apparatus and evaluation tests are performed in the substantially similar manner to those of Example 1, except that the electrophotographic photoreceptor of Example 3 is used in place of that of Example 1.
  • a melamine resin and 95 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 210 parts by mass of cyclohexanone; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • Example 4 After that, 0.2 parts by mass of “NACURE 5225” (trade name, manufactured by King Industries, Inc.) that serves as a catalyst is added to the mixture so as to prepare a coating liquid for forming a protective layer. Then, an electrophotographic photoreceptor of Example 4 is produced in the substantially similar manner to that of Example 1, except that the coating liquid for forming a protective layer is replaced with that herein formed. Further, preparation of an electrophotographic apparatus and evaluation tests are performed in the substantially similar manner to those of Example 1, except that the electrophotographic photoreceptor of Example 4 is used in place of that of Example 1.
  • a guanamine resin and 95 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 210 parts by mass of cyclopentanone; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • a melamine resin and 79 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 210 parts by mass of cyclopentanone; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • a melamine resin and 95 parts by mass of the compound I-16 shown above as a charge-transporting material are added to 140 parts by mass of tetrahydrofuran and 33 parts by mass of toluene; after these are sufficiently dissolved and mixed, the suspension liquid of tetrafluoroethylene resin particles is added thereto. After agitation and mixing, the resulting mixture is subjected to a dispersing treatment with a high pressure homogenizer (trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.) equipped with a feed-through chamber having fine flow channels at an elevated pressure of 700 kgf/cm 2 repeatedly 20 times.
  • a high pressure homogenizer trade name: YSNM-1500AR, manufactured by Yoshida Kikai Co., Ltd.
  • ratio of thermosetting material and “ratio of charge-transporting material” that are designated by the mark (*1) are the ratios of contents with respect to the total solid content of the overcoat layer excluding the content of the fluoro-resin particles (tetrafluoroethylene resin particles) and the content of the fluoro-alkyl group-containing copolymer.
  • the ghost indicates an occurrence of remaining of an exposure hysteresis (exposed image) of the preceding printing cycle in the succeeding printing cycle upon forming images. The ghost is evaluated in accordance with a sensory rating in which the printed image is compared with a reference image.

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  • Chemical & Material Sciences (AREA)
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  • Spectroscopy & Molecular Physics (AREA)
  • Photoreceptors In Electrophotography (AREA)
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US20130017479A1 (en) * 2011-07-15 2013-01-17 Xerox Corporation Phenolic phosphite containing photoconductors
US8507161B2 (en) * 2011-07-15 2013-08-13 Xerox Corporation Phenolic phosphite containing photoconductors
JP2013088714A (ja) * 2011-10-20 2013-05-13 Fuji Xerox Co Ltd 電子写真感光体、プロセスカートリッジ、及び画像形成装置
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EP2790059A3 (en) * 2013-03-07 2014-12-24 Canon Kabushiki Kaisha Electrophotographic photosensitive member, electrophotographic apparatus, process cartridge, and condensed polycyclic aromatic compound
WO2015077061A1 (en) 2013-11-25 2015-05-28 Dow Global Technologies Llc Moisture-and peroxide-crosslinkable polymeric compositions
WO2015200016A1 (en) 2014-06-27 2015-12-30 Dow Global Technologies Llc Stabilized moisture-curable polymeric compositions
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